Packet technology

ABSTRACT

A disposable flexible envelopelike container and a new sheet material are taught. The container is convertible to a pocket applicator for applying packaged messy spreadable compositions such as various polishes, cleaners, pastes, oils, paints, stains, waxes, and many other compositions. The envelopelike container is easily manufactured by automated techniques. It has opposing walls formed of flexible sheet material. The sheet material preferably employed has a flexible self-supporting organic polymeric film and an exposed recesscontaining layer over one surface of that polymeric film. Seals unite peripheral portions of the opposing walls of the envelope together. One edge is only temporarily sealed; and the others are permanently united. Earflaps extend beyond the temporary seal. In use, a person grips the earflaps and pulls them apart to rupture the temporary seal and thereby convert the envelopelike container into a pocket. This pocket is then reversed or inverted to place the spreadable composition exterior to the inverted pocket. One then inserts one&#39;&#39;s fingers in the inverted pocket, which now becomes an applicator, and then applies the spreadable composition. The earflaps serve as a shield against unwanted contact with the spreadable composition during application of it to a surface. The length of the temporary seal and its relationship to the depth of the envelope cavity is critical to permit convenient reversal or inversion of the pocket during the step of converting the container into an applicator.

United States Patent Primary Examiner-Lawrence Charles Attomey-Robert C.Baker Baker et al. Mar. 7, 1972 [54] PACKET TECHNOLOGY ABSTRACT [72]Inventors: Mary Joan H. Baker; Robert C. Baker, A disposable flexibleenvelopelike container and a new sheet both of 1831 Summit Avenue, St.Paul, material are taught. The container is convertible to a pocketMinn. 55105 applicator for applying packaged messy spreadablecompositions such as various olishes, cleaners, pastes, oils, aints,[22] Flled: 1969 stains, waxes, and man other compositions. p

[21] Appl 806983 The envelopelike container is easily manufactured byautomated techniques. lt has opposing walls formed of flexible 52 us.c1. ..401/7, 206/56 AA, 401/132 Sheet material The sheet materialPreferably p y has a 51 Int. Cl. ..A46b 5/04 flexible pp rting organicpolymeric film and an exposed [58] Field 61 Search ..401/7, 132; 206/56A; 15/104, recess-wmaining layer Over one surface of that P Y 15/94film. Seals unite peripheral portions of the opposing walls of theenvelope together. One edge is only temporarily sealed; 56] Re'erencesCited and the others are permanently united. Earflaps extend beyond thetemporary seal. UNITED STATES PATENTS In use, a person grips theearflaps and pulls them apart to rup- 2,232,783 2/1941 Hausheer ..206/56AA ture the temporary seal and thereby eenvert the envelepelike2,954,116 9/1960 M et L 206/56 AA container into a pocket. This pocketis then reversed or in- 2,997,166 8/1961 Pratt 206/56 AA verted to placethe spreadable composition exterior to the in- 3,l76,338 4/1965Homburger... 401/7 verted pocket. One then inserts ones fingers in theinverted 3,190,436 6/1965 Diamant 206/165 P whieh new becomes anapplicator, and then pp 3 230 420 10/19 w 15 104 94 the spreadablecomposition. The earflaps serve as a shield 3,369,267 2/1968 Friedlandet al ..401/132 x against unwanted eenteet with the spreadablecomposition during application of it to a surface. The length of thetemporary seal and its relationship to the depth of the envelope cavityis critical to permit convenient reversal or inversion of the pocketduring the step of converting the container into an applicator.

19 Claims, 12 Drawing Figures PACKET TECHNOLOGY This invention relatesto a new sheet material, a new package structure in the form of adiscardable flexible envelopelike container convertible to a pocketapplicator, and methods for making the new package structure as well asmethods for using it.

The invention provides easily used discardable applicator packages formessy spreadable compositions such as shoe polishes, metal polishes, orother polishes, various cleaners, cleansers, cosmetic preparations,germicidal mixtures, medicinal compounds, toiletry items, polishremovers, pastes, creams, lotions, oils, paints, waxes etc.

Convenience-type packaging of various ingredients in small single use ordiscardable applicator packets has been proposed heretofore. Anillustrative teaching is set forth in van Boytham U.S. Pat. No.2,621,784. Van Boythams structure is that of a sealed envelope which isfully opened and flattened in the palm of ones hand to expose aninterior special flannelette applicator pad occupying the centralportion of the open envelope layer and suitably cemented to it. Aspecial finger-receiving pocket is created on the under side of vanBoythams open envelope by an extra fold of material. A furtherillustrative approach is that in Wanzenberg US. Pat. No. 3,280,420,where a multifolded packet is set forth having special areas and limitedtreated surfaces for the application of shoe polish and the polishingthereof.

One objection to prior art single-use applicator packages or packets isthe complexity and therefore the expense of manufacturing them. Anotherobjection is that their arrangement of elements militates againstcareful and neat application of their contents. For example, the vanBoytham flannelette applicator pad occupies most of the open area of hisenvelope layer, and extends into the palm area of ones hand, which tendsto increase the risk of spreading ingredients from the treated pad toundesired areas. Controlled and neat application of ingredients isnormally only accomplished with the tips of ones fingers. The Wanzenbergpackage structure is so complex as to invite almost a professionalapproach to shoe shining instead of a simple quick and neat job. Stillfurther, known applicator package structures of the prior art are lessthan effective to save one from messy contact with the packagedingredients during application of those ingredients to a surface. Theseand other disadvantages have militated against practical adoption ofprior art applicator packets for messy compositions. In short, despitethe long standing need for effective single-use applicator packets, andthe desire for them by consumers, a truely practical and economical andsimple convenience-type single-use package-applicator for messyingredients, effective to save one from messy contact with thoseingredients, has not heretofore, insofar as is known, been available.

This invention provides a novel solution to this problem. The applicatorpacket of the invention is economical to manufacture, uncomplicated instructure, easy and fast to use in a neat manner, and fully effective topermit application of packaged ingredients neatly upon a surface withoutcontaminating or staining ones fingers or hands. Still further benefitsof the invention will be evident as this description proceeds.

This new applicator package is preferably formed using especiallyprepared flexible sheet material of the invention. This preferred sheetmaterial has a flexible self-supporting organic polymeric film, and anexposed recess-containing layer over one surface of the polymeric film.Preferably, the side of the sheet material having that recess-containinglayer (that is, recess-containing structure) is hermetically heatsealable to itself over all portions thereof. Thus, not only is therecess-containing layer side capable of serving as an applicator forpolishing or coating a surface with messy material, it is also capable,in the preferred embodiment, of being sealed hermetically to itself byheat. Even when not hermetically heat scalable to itself, seals ofpermanent as well as temporary character are possible betweenface-to-face oriented areas of the recess-containing side of a sheetmaterial in an envelope structure of the invention, as will beexplained.

The new disposable flexible envclopelike applicator and container isextraordinarly simple to make. Continuous automated manufacturingtechniques are possible. Multitudinous folding is avoided, which reducesraw material and manufacturing expenses. Yet the resulting new packagestructure is fully effective as a container for the marketing ofsingle-use quantities of messy ingredients and is easily converted intoan applicator pocket which permits controlled application of thoseingredients to other surfaces without need for messy finger contact withthe ingredients.

This new package structure is in the nature of an envelope havingopposing walls formed of a flexible sheet material. A spreadable messycomposition is enclosed within the envelope cavity between the opposingwalls of the container. Recesscontaining layer means is fixed within theenvelope cavity (e.g., the recess-containing layer side of the flexiblesheet material) and provides a carrier structure or surface for themessy composition in the envelope cavity.

The sheet material forming the opposing walls is united along allportions thereof immediately adjacent the peripheral limits of theenvelope cavity, with all of the portions which are in face-to-facerelationship adjacent those peripheral limits being united by sealstructures. The expanse of the sheet material forming each of theopposing walls of the container is sufficient in size to extend beyondthe seal structure along one edge or peripheral limit of the cavity toform outwardly projecting earflaps. The seal structure along that oneedge is temporary and rupturable, whereas the other seal structures ad-.jacent the peripheral limits of the envelope cavity are permanent innature. The edge seal which is temporary is at least 5 centimeters andno greater than about l5 (or possibly but rarely 20) centimeters intotal length; and the depthdimension of the envelope cavity downwardlyfrom that temporary seal edge is no greater than about 10 centimeters,and in any event, is less than the length of the temporary seal.

In use, the earflaps are gripped by a thumb and forefinger and drawnapart to rupture the temporary seal of that one edge and simultaneouslyform the container into a pocket. The pocket is then turned inside outto place the recess-containing layer means holding or carrying thespreadable composition on or in it exterior to the inverted pocket. Thena person inserts his fingers into the inverted pocket, where they areprotected against contamination during hand application of thecomposition. The earflaps serve as a shield against unwanted contactbetween the composition and the person applying the composition evenwhen an earflap is gripped between ones thumb and palm of hand to guidemovement of the pocket applicator over a surface.

The invention will further be described by reference to a drawing, madea part hereof, wherein the several figures are each schematic sketchesor illustrations as follows:

FIG. I is a side view of a package structure according to the invention;

FIG. 2 is a cross section taken on line 2-2 of FIG. 1, with a personsfingers shown in phantom;

FIG. 3 is a further cross-sectional view along the same plane as FIG. 2,including a persons fingers in phantom, showing the character of thepackage structure after it has been converted into a pocket;

FIG. 4 is likewise a cross-sectional view along the same plane as FIG.2, including a persons fingers in phantom, showing the character of thepackage structure after it has been turned inside out and therebyconverted into a pocket applicator; I

FIGS. 5 and 6 are side plan views of alternate package structuresaccording to the invention;

FIGS. 7 and 8 are cross-sectional views of illustrative flexible sheetmaterial of the invention;

FIG. 9 is a top plan view illustrating a coating pattern for a method ofmanufacture;

FIG. 10 is a side plan view illustrating a further method ofmanufacture;

FIG. 11 is a top plan view ofthe showing in FIG. and

FIG. 12 is an enlarged fragment of a package illustrating a temporaryheat seal structure.

Referring to the drawing, and particularly FIGS. 1 and 2, the newpackage structure is in the form of an envelopelike container 10 havingopposing walls 1 l and 12 of flexible sheet material. A small quantityof a spreadable composition 13 is within the envelope cavity of thecontainer. This envelope cavity is between the opposing walls 11 and 12of the flexible sheet material and is defined by those walls.

Referring to FIGS. 2 and 7, an illustrative preferred unitary sheetmaterial useful in the practice of the invention is one having aflexible self-supporting, preferably nonfibrous, nonabsorbent,substantially nonporous organic polymeric film 14 (such as Mylar"), andan exposed recess-containing layer 15 (preferably a layer of randomfibrous elements such as polyethylene fibers) scattered over and unitedto essentially all portions of one surface of the polymeric film, sothat the recess-containing layer is essentially coextensive with thebase. The recess-containing layer side 15 forms the interior surface ofwalls 11 and 12 of the package. That recess-containing side ispreferably somewhat absorbent in character; and unless otherwiseindicated by the context, absorbent, as used herein in connection withthe recess-containing layer includes either or both absorbent andadsorbent phenomenon. (The term nonabsorbent, which is sometimes used inconnection with the polymeric base film, is not, however, to beconstrued as excluding the possibility of a surface of that filmexhibiting some surface adsorbent phenomenon). The character of therecess-containing layer serves to hold the messy composition more orless in position or partially within limited recesses or openingsbetween elements (such as fibers) forming the structure of that layer.Recess-containing refers to recess openings such as irregular spaces ofminute or small character between fibrous elements of a layer (e.g.,deposited as a layer by flocking), or to a uniform pattern of embossedin dents or recesses in a base film, or even to openings or passages inrelatively thin spongelike or porous sheet material. In effect therecess means of the structure comprises a plurality of mini-recesses.

Sheet material of opposing walls 11 and 12 is united (preferablyhermetically, but not necessarily so where nonfluid constituents arepackaged) along all portions thereof immediately adjacent the peripherallimits of the envelope cavity itself. Illustratively, the bottom edge 16simply consists of a fold of the sheet material; and this foldpermanently unites opposing walls 11 and 12 along that bottom orperipheral lower edge 16. Portions of the recess-containing layer sideof the sheet immediately adjacent the lateral peripheral limits of theenvelope cavity are united together by permanent seal structures; andthis is illustrated by permanent seals '17 and 18 at each lateralextremity or end of the cavity. Temporary seal 19 extends across the topof the cavity uniting the face-to-face oriented sides of each wall atthe upper peripheral limits of the cavity.

To be especially observed is that the expanse of the sheet materialforming each opposing wall 11 and 12 of the envelope cavity issufficient in size to extend outwardly beyond the temporary sealstructure 19 which is along the upper peripheral edge or one edge of theenvelope cavity. The extension beyond temporary seal 19 is in the formof outwardly or upwardly projecting earflaps 20 and 21; and thisextension must be at least a half-centimeter beyond the temporary seal19. The extension normally should be at least about I centimeter beyondseal 19, or even at least 1.5 centimeters (up to possible 3 or 5 or even8 centimeters beyond seal 19). The greater extensions provide a surfacewhich sometimes may be useful for finish shining after application ofmessy ingredients. If desired, the earflaps may be of unequal size so asto facilitate separation for hand gripping. They may be shaped in theform illustrated by the dash line 22 in FIG. 1. Preferably, however,earflaps 20 and 21 extend outwardly at least about I centimeter alongthe entire length of temporary seal 19 and suitably terminate more orless in a straight edge 23, even though seal 19 may be arced or elevatedat its central portion. Further, the earflaps preferably are not unitedalong lateral edges 24 and 25. Thus, the permanent seals 17 and 18defining the lateral peripheral limits of the envelope cavity usuallywill not extend out or upwardly any great amount beyond their juncturewith the temporary seal 19 (with the possible exception that, when anauxiliary seal structure 26 as illustrated in FIG. 5 is used, thepermanent seals 17 and 18 as illustrated in FIG. 1 suitably merge withsuch an auxiliary seal).

The temporary seal along the one edge 19 of the envelope cavity isrelatively easily rupturable by pulling apart earflaps 20 and 21. Seal19 is at least about 5 centimeters and no greater than about 15 (orrarely 20) centimeters in total length. Usually it is at least about 7centimeters long but not longer than about 10 or 12 centimeters. It isalways at least about as long as the longest dimension of the envelopecavity (e.g., between end seals 17 and 18).

The depth dimension of the envelope cavity itself, measured downwardlyfrom the temporary seal 19, is never greater than the length of thetemporary seal 19 and generally not in excess of about 10 centimeters.Envelope cavities of greater depth have been usually found impracticalfor convenient reversal. Usually, the depth dimension (taken at thegreatest distance between seal 19 and the bottom edge 16 of the cavity)is not in excess of about 8 centimeters, with a depth dimension betweenabout 2 and 4 (or sometimes as high as 6) centimeters being mostpreferred. The limited depth (preferably no greater than two-thirds oreven one-half the length of the temporary seal) for the cavity servesnot only to contribute to ease of reversal, in the manner hereinafterdescribed, but also contributes to concentration of the messy spreadablecomposition to fingertip areas for application purposes, as will beevident from the teaching to follow.

In use, an individual desiring to apply a spreadable composition withinthe cavity of the package structure first grips each earflap 20 and 21between a thumb and forefinger and pulls those earflaps 20 and 21 apart,thereby rupturing the long temporary seal 19 along the top of theenvelope cavity. The fingers shown in phantom in FIG. 2 illustrate howthis is done. The result'is that seal 19 is opened to convert thepackage structure into a pocket, which is illustrated in FIG. 3. Thenthe resulting pocket is inverted or turned inside out. This can be donein almost a continuous motion from the rupturing of the temporary seal19. It is accomplished by continued gripping of the earflaps 20 and 21between thumb and forefinger and holding them apart while simultaneouslyusing the other fingers of one or both hands to press the walls 11 and12 and the bottom edge 16 of the open pocket upwardly to turn the pocketof FIG. 3 inside out. After being turned inside out, the structure isconverted to an applicator which has the appearance, in cross section,as illustrated in FIG. 4. One then inserts two or three or all fingersof one hand (depending upon the size selected for the package structure)in the inverted pocket applicator and grips an earflap by pressing onesthumb against it and against the palm of one s hand. This is shown inphantom in FIG. 4. Thus the inverted pocket, which now has become anapplicator, may be firmly gripped during the step of using one'sprotected fingers to apply the spreadable composition to a surface. Thelimited depth of the envelope cavity of the package structure asmarketed in commerce serves to concentrate the messy ingredients on theexterior of the pocket applicator to an area where fingertip applicationof them is conveniently accomplished. The earflaps of the invertedpocket further serve as a shield against unwanted contactbetween thespreadable messy composition and the person applying that composition.This is so even when an earflap is gripped, as just noted, between thumband palm of hand to guide movement of the pocket applicator over asurface.

To be noted is the fact that seals 17 and 18 at the lateral terminalends of the elongated envelope cavity are preferably such as to taperinwardly (or toward each other) from their widest point at theirjuncture with the ends of temporary seal edge 19 to the bottom edge 16of the envelope cavity. Al-

ternately these end seals 17 and 18 may be essentially straight incharacter; but tapering, as just noted, greatly facilitates convenientreversal of the package in the manner illustrated in FIGS. 2-4inclusive. Also, the inverted pocket is less apt to have nonreversedsmall corner sections between the bottom edge 16 and end seals 17 or 18.While such small sections can be inverted by spreading ones fingers intothose areas after inverting or reversing the main body of the pocket,the taper or slope of seals 17 and 18 contributes to the ease ofinverting and reduces the likelihood that a small portion of the messyingredients will be unavailable for application because of a nonreversedcorner section. Much greater tapering than that illustrated maysometimes be desirable.

A further and most significant feature of the structure illustrated inFIG. I is in the design or shape of the temporary seal 19. Thattemporary seal 19 (both in FIG. 1 and in FIG. 6) is arced or taperedupwardly (i.e., outwardly from the envelope cavity), suitably in curvedor straight lines, to a peak or elevation 26, suitably centrallylocated. This limited section or peak provides a starting point forconvenient rupture of seal 19.

FIG. 5 illustrates a package formed using a cylinder of polymeric film,which results in lateral ends numbered 17 and 18 of the envelope cavitybeing inherently united (e.g., folds). Temporary seal 19 is shown as astraight seal, which is less preferred, but is extremely simple andeconomical. Illustratively, outer portions or peripheral extremities ofthe earflaps (only flap 21 being visible for the view of FIG. 5) may becontinuously united by a contoured strong heat seal 26; but when this isdone, some separation means, such as a tear strip 27 with a projectingpart as a grip-tab, should be located between the united earflaps. Tearstrip 27 preferably extends partially into the area of seal 26 (whichassists in holding tear strip 27 in position). An extra or auxiliaryseal such as seal 26 provides a further fully sealed chamber beyondtemporary seal 19 to protect against loss of cavity contents in theevent of accidental rupture of temporary seal 19 during shipment. Tearstrip 27 permits convenient separation of the earflaps; and where thetemporary seal 19 is not damaged, the flaps are clean to serve theopening and protective functions as aforediscussed. The bottom edge ofthe envelope cavity in FIG. 5 is united by a permanent heat seal 28,which in this figure also serves to bond and permanently hold one edgeof a separate recess-containing layer means as a free tongue in thecavity (said tongue suitably being a sheet of fibers or spongelikematerial having the approximate shape within the envelope cavity of FIG.5 as shown by the dash lines upwardly from seal 28 in FIG. 5).

FIG. 6 illustrates an envelope cavity of essentially elliptical shape,formed by providing contoured permanent seals 17 and 18 forapproximately the lower half of each end of the ellipse and a continuousstretch of permanent seal 28 along the bottom, with an arced temporaryseal 19 across the top of the ellipse and partially into the end curvedportions thereof to meet the permanent end seals.

Sheet material useful to form packet structures of the invention musthave a self-supporting base layer or film 14 of flexi ble organicpolymeric character. The base polymeric film is preferably very thin(e.g., preferably not over about 80-100 microns thick). Where it isextremely flexible, thicker films (200 or 300 or even possibly as thickas 500 microns) may be used without interferring with pocket inversion.The film structure is strong and tear resistant in use; and therefore itis tough. It may be as thin as about 5 microns, but usually will liewithin the range of thickness of about l0 microns up to about 40 or 60microns. (An illustrative base polymeric film structure is quarter milor about 6-micron Mylar coated with a lO-micron heat seal polymericresin layer or film). The film is not fibrous matt in character,although it may contain embedded fibrous or filament reinforcing. Itdoes not serve per se as an absorbent material; and thus isnonabsorbent. It should not react with packaged ingredients. It issubstantially nonporous or substantially fluid impervious in the sensethat, in the packet form, it will substantially prevent migration orleakage of the particular composition packaged. Appropriate fluidimperviousness to a particular fluid-containing composition to bepackaged may be imparted or enhanced, as by employing more than one typeof material (either as a laminate or in admixture) in the structure ofthe base polymeric film. In essence, the base film serves as asubstantially impervious barrier to escape of the particular compositionwhich is packaged.

The flexible base film structure may be essentially clear andtransparent or tinted or dyed and transparent. It may be pigmented toobscure packaged contents. Inorganic coloring pigments may beconcentrated in a single strata of the base structure. A film ofvapor-deposited metal (e.g., aluminum) may be placed on the basepolymeric film, or embedded between layers. Metal foils, however, aretoo stiff. An embedded vapordeposited metal film (which has theappearance of being substantially continuous) may serve as a goodbackground for printed instructions on sheet material.

A desirable base film structure is one having a substantiallynonthermoplastic essentially non-heat-sealable polymeric film (such as,for example, a polyethylene terephalate type film) to which athermoplastic and readily heat-sealable polymeric film or coating (suchas, for example, a polyethylene or polyvinylidene chloride) ispermanently adhered by any known suitable technique (e.g., primers,chemical reaction, etc.). The films of Scothpak," which is a trademarkof Minnesota Mining and Manufacturing Company, are of such compositeunitary character. FIG. 8 illustrates a polymeric film 14 (e.g., 15-20microns thick) which is not heat sealable or only difficulty heatsealable, but which is coated with a thin film 29 (e.g., 5-10 micronsthick) which is readily heat sealable. (Where desired, the heat sealableresin layer in such a structure may be relatively thicker, such as 60 ormicrons; or additional layers of heat-sealable resin may be added, e.g.,a coating of acrylic resin solids such as WN-80 of Rohm & I-IaasChemical Company.) Plasticizers may be incorporated in a heat-sealablelayer. They generally serve to lower the temperature at which heatsealing may be effected. However, the selection of plasticizers, whichis a well-known art, will be effected to avoid those which migrate andcontaminate packaged ingredients. Usually, the thickness of aheat-sealable resin coating will not exceed about 30 microns; and thepreferred total thickness of the base film as a structure including anyresin film coating will not be over about 60 microns. Base structures asthin as possible form the more easily handled packages.

The base polymeric film may itself be formed wholly of heat-sealablematerial. Useful to this end are thermoplastic materials or compositionsbased upon polymeric resins such as polyethylene, polyvinyl chloride,polyamide-type resins (such as formed by reacting a polybasic acid witha polyamine; nylon), nylon-reinforced vinyls, and a variety of others.

Upon one side of the base film 14 (or a composite base film such asillustrated in FIG. 8) is preferably united a recess-containing layer15, which preferably is soft but need not necessarily be napped orpiled. It may be porous or foam resin material of spongy character, withor without fibrous elements (e.g., U.S. Pat. No. 2,671,743), or it maybe formed as an irregular layer of nonthermoplastic or thermoplasticfibrous elements, or both. The overall thickness of the layer structurecharacterized as the recess-containing layer as united to the basedesirably is maintained as thin as possible (e.g., up to 50 microns) andis preferably not greater than about 200 or possibly 300 microns. It maybe and usually is irregular in thickness. It may be even as thin as onlya few microns (especially when formed by flocking fibrous elements orembossing recesses in a base polymeric film). Thicker recess containinglayers united to a base film, e.g., 500 microns or even 1,000 microns (amillimeter) are sometimes useful; but such thicker layers (preferablyformed of shiftable fibers on a back film to facilitate pocketinversion) generally are unnecessary and add expense.

The material of the recess-containing layer, and the character of thebase film itself, determines or may limit the useful type of sealstructures. But where the base film itself or a coating on it isthermoplastic and heat scalable, and where that heat-scalable film is ofsufficient thickness (e.g., about 60 microns), nonthermoplastic fibrouselements (such as cellulosic fibers, e.g., paper, rayon or like fibers;or even glass fibers where mild abrasive-type action is needed or is nota disadvantage) may be employed in limited quantities while retainingheat scalability for the structure. Flocking of nonthermoplastic fibrouselements on a softened thermoplastic layer is a suitable technique tobond fibrous elements in place; and heat sealing of the fibrous side ofthe structure to itself may still be accomplished where the thickness ofthe heat sealable coating is sufficient to swallow up or penetratethrough the fibrous elements during the step of applying modest pressureand the necessary softening heat during heat sealing (e.g., varyingnormally from about 40 C. up to about 150 C. or 200 C, or even possibly300 C., depending upon the softening temperature of the heat-scalablematerial employed).

Where a preponderance (e.g., over 50 percent by volume) of the fibrouselements employed are nonthermoplastic-even though they may be bonded tothe base film by thermoplastic material-it is suitable to employ verythin base materials and to form seals by adding adhesive materialbetween the portions of the sheet material to be sealed. This may beaccomplished in mass production as illustrated in FIG, 9. Adhesivematerial 30 (preferably heat activatable or thermoplastic) is solventcoated on the fibrous side of the sheet material 31 in a repetitivepattern while the sheet material is in flattened stock form prior to thestep of forming any seals. Volatiles are removed from the coated pattern(which will be noted from FIG. 9 to be in the shape of the seals l7, l8and 19 illustrated in FIG. 1),

Also illustrated in FIG, 9 are droplets or pellets 32 of the ingredientsto be packaged. To reduce mess during manufactun ing steps, it issuitable to cool or even freeze liquid-type spreadable compositions in,for example, rod form. Small pellets may be cut from the rod andautomatically positioned as illustrated in FIG. 9; or small quantitiesof a cooled mass may be dispensedby extrusion as a relativelynonflowable droplet 32 into the proper locations for packaging, asillustrated in FIG. 9. Another suitable technique is that of temporarilyencapsulating measured quantities of the ingredients to be packaged.Still another, where only minute quantities are required, is that of arotogravure or even a lithographic transfer approach.

After volatiles are removed from the coated pattern 30 and the pelletsor droplets 32 in position, the lower half of the sheet stock 31 isfolded over the upper half and the folded structure is passed between alower pressure drum and an upper drum having a projecting peripheralpattern of heat elements which mates with the coating pattern 30 as thefolded sheet stock is passed through.

In connection with FIG. 9, a further suitable approach is that ofcoating upon a flat stock formed with heat-scalable fibers a relativelywide strip (e.g., the entire edge portion of the flattened stock), fromabout 1 centimeter up to about onefourth the width of the stock, with arelatively non-heat-sealable resin (or one softened only above thetemperature at which the heat sealable fibers are softened). Thiscontributes to the formation of excellent temporary heat seals which areneatly separable, as will be discussed in connection with FIG. 12.

Alternately, the quantity of adhesive in the pattern for seal 19 (asillustrated in FIG. 9) may be reduced in comparison to the quantity orwidth of coating for the areas to form permanent seals 17 and 18.Further, a different type of adhesive (e.g., one of relatively lowmolecular weight, lower softening temperature and low internal strength)may be coated in the pattern for the temporary seal 19. Even' possibleis the use of room temperature pressure-sensitive adhesive for temporaryseal 19; but seals of such material generally are not as reliable asheat seals in terms of handling the packet in commerce.

They may be used, however, where the packaged composition does notcontain ingredients capable of attaching or separating the sealprematurely. Also possible is the insertion of a strip in the nature ofa tear strip for use to aid separation of a temporary seal.

Preferably, thermoplastic fibrous elements 15 are employed in thefabrication of a recess-containing layer on base polymeric films. Fibersof thermoplastic cellulose acetate, polyvinyl acetate, polyethylene orother thermoplastic material may be flocked upon a base polymeric filmand bonded thereto either by partial melting or softening of flockedthermoplastic fibers to gain a bond to base film of nonther moplasticcharacter, (preferably suitably primed). or by heat softening a thinthermoplastic base film or coating. While not always necessary, thethermoplastic fibers employed should preferably soften at a temperatureno higher than about that for the softening of the thermoplastic resincoating. This relationship is important where the fibers are per se heatsealed (e.g., fused) in the formation of seals for a packet. Aninteresting sheet structure is that carefully formed by lightlycalendering a mat of polyethylene fibers at room temperature and thenpassing the compacted layer over a heated drum at a temperaturesufficient to flow the contacting surface of the mat into a continuousfilm while at the same time causing the opposite surface of the mattedfibers to relax or even expand somewhat outwardly from their compactedcalendered condition.

Soft fibrous layers of heat scalable character may suitably be preparedby the Rando-Web technique, or by carding fibers into a porous mat(preferably of overall thickness not above microns). A soft fibrouslayer of randomly oriented thermoplastic cellulose acetate fibers (e.g.,fibers of about 3- denier size and one-half to 2 inches in length) maybe laminated to a base film (e.g., a cellulose acetate film united to apolyethylene terephthalate base) by passing the base film over a heateddrum while feeding the layer of fibers to it, preferably under slightbonding pressures. To reduce costs, a small quantity of nonthermoplasticfibers (up to or approaching about 30 percent or so of the total fibervolume) may be incorporated in a thermoplastic fibrous layer withoutobstructing the heat seal properties of such a thermoplastic fibrouslayer; and in that sense, the layer still is characterizable asconsisting essentially of thermoplastic fibers or fibrous elements.

The most economical and practical sheet structures of the invention arethose wherein the recess-containing fibrous layer, instead of beingwoven, is simply a randomly oriented layer of nonwoven fibers or fibrouselements. Sheet material formed using thermoplastic heat scalable fibers(e,g., thermoplastic at a temperature between about 40 C. and about 300C.) and preferably a thermoplastic heat-sealable polymeric film (orcoating on the fiber-carrying side of a nonthermoplastic base film) isespecially adapted for movement through automatic heat sealing andpackage forming apparatus.

An automatic heat-sealing manufacturing technique is illustratedschematically in FIGS. 10 and 11, where a flattened longitudinal stripof sheet stock 33 is shown as being folded upwardly upon itself inface-to-face relationship (along a' line approximately at the center ofthe longitudinal strip) by suitable lateral guide rollers 34 as the flatsheet stock is indexed through apparatus. Then heat seal elements 35 and36 move together to form a relatively wide permanent heat.seal 37 atlongitudinally spaced intervals along the folded stock. These permanentseals 37 extend transversely from and intersect the fold line so as toform a series of pockets along the longitudinal folded length of thesheet material. The distance out from the fold line to which thesepermanent seals extend is limited by the size relationshipsaforediscussed for the envelope cavity of the packages. The line ofpockets, separated by seals 37, are then forced open by guide discs 38and 39; and simultaneously the line of pockets is lowered in its travelas compared to the line of travel at seal elements 35 and 36. Thisaction serves to bulge the sides of the pockets outwardly for receptionof a measured quantity of the spreadable composition to be packaged. Themeasured quantity is dispensed in a shot manner by a plunger-typeextruder 40. Thereafter, the line of pockets is passed between heatsealing coacting rolls 41 and 42, which add the narrow line of temporaryor light heat seal 19 in a longitudinal direction across the top of theenvelope cavity of the package. The line of temporary light heat sealconnects terminal portions of the permanent seals opposite the fold lineor edge. Cutter knives, not illustrated, are used to sever the envelopepackages transversely through the permanent seals 37 along illustrateddash line 43. If desired, the cut along dash line 43 may bediscontinuous, in the form of a line of dots or dash cuts, therebymaintaining the packages, for marketing purposes, in a continuous stripfrom which the consumer can easily sever a package at the time of use.

Temporary seals such as illustrated at numeral 19 in the various figuresof the drawing are conveniently formed by employing relatively thin ornarrow lines (e.g., 2 millimeters width) of heat seal as compared to thepractice of employing relatively wider lines of heat seal (on the orderof 4 or 5 millimeters or even I centimeter or more in width) forpermanent heat seals, Since the fibrous character of heat-sealablefibrous layers is largely destroyed by fusion in the heat seal area, theease of rupture of temporary heat seals 19 is sometimes desirablyimproved by incorporating additional structure in that area. Withoutadditional structure in that area, the rupture of temporary heat sealsis sometimes accompanied by the formation of strings of tear or rninutehairy protections along the joined surfaces of temporary seal. Also,additional structure is preferably employed where the base film consistsof material which is thermoplastic at the temperature of heat sealingfor the fibers (as distinguished from structures where the fibers areheat sealed at temperatures below the softening temperature for the basefilm or where the base film structure includes an essentiallynonthermoplastic film).

In FIG. 12, which is an enlarged fragment of a package, a specialtemporary heat seal structure 19 is illustrated. In that structure,fibrous surface of each sheet material 44 and 45 is joined to anintermediate striplike layer 46. Strip or layer 46 is thermoplastic andextends as a narrow strip down the length of the temporary seal 19.lllustratively, its structure may be such that it is of graduallyvarying composition from one surface to the other. The surface of strip46 to which fibers 15 of one sheet 44 are bonded may be relatively highmelting, whereas the surface to which fibers 15 of the other sheet 45 isbonded may have an adhesive activation temperature comparable to theheat seal activation temperature of the fibers 15 of the sheet material.Thus, during the heat sealing of temporary seal 19 (which in thisstructural relationship may be accomplished in a relatively wide widthup to the width of strip 46), the fibers of sheet 45 fuse into andpermanently unite with the surface of strip 46 adjacent thereto; but thefibers of sheet 44 merely fuse together and into contact with thesurface of strip 46 adjacent thereto, without merging or blending withthe material of that surface. The interface between fused fibers ofsheet 44 and the adjacent surface of strip 46 therefore is relativelyeasily ruptured, but is a hermetic seal prior to being ruptured.lllustratively, a suitable strip for a package formed of sheet materialcarrying thermoplastic cellulose acetate fibers is one having celluloseacetate as the material exposed on one side and a higher melting butpossibly still a thermoplastic nylon as the material exposed on itsopposite surface. A variety of resin combinations are possible, with thecomposition intermediate the surface portions being a blend oradmixture. Manufacture ofa strip 46 is easily accomplished by coatingthe lower softening or melting thermoplastic, (after elevating it to thesoftening temperature of the higher melting thermoplastic) as a hot meltupon a thin film of the higher melting thermoplastic. Instead ofemploying a separate strip 46, similar structural results are madepossible by coating a striplike layer of resin (having a highersoftening temperature than the softening temperature of thethermoplastic fibers of the sheet stock) in a pattern such asillustrated for the temporary seal 19in FIG. 9. One way of accomplishingthis is by solvent coating.

If desired, the sheet material employed in forming the packets mayitself be free of a recess-containing layer unified therewith and aseparate recess-containing layer means bonded in position, as by heatsealing, at the time of forming the packets. (Also, even when the sheetmaterial employed is one having fibers or the like unified as a layerthereto, additional recess-containing layer means may be incorporated inthe packets.) This has been illustrated in connection with FIG. 5, wherethe recess-containing layer means is in the nature of a tongue-flap of arecess-containing sheet formed either of heatsealable ornon-heat-sealable material. A nonwoven (or even woven) mat of fibers ora porous spongy sheet material may be employed as a separaterecess-containing sheet. Such a sheet may even be as thick as about 5millimeters, but generally will be as thin as possible (e.g., or 200microns) consistent with therecess volume required. Thickness generallyshould not exceed I or 2 millimeters, and usually not even ahalf-millimeter or 500 microns.

The separate recess-containing sheet may be handled as a continuousstrip of material and feed with a base polymeric film throughmanufacturing steps such as discussed in connection with FIGS. 9, 10 and11. Suitably, a relatively narrow band of a recess-containing separatesheet or layer material (e.g., of a width up to about three-fourths oreven the entire depth of the envelope cavity contemplated) may beinserted as an intermediate layer between the walls of a polymeric basefilm chosen for a string of packets (such as described in connectionwith FIGS. 10 and 11). If the recess-containing separate sheet is, forexample, a heat-scalable mat of thermoplastic cellulose acetate fibers,the formation of heat seals 37 between a string of packets, asillustrated in FIGS. 10 and 11, can also effectively fuse the fibers ofthe band or width of cellulose acetate in the area of heat seals 37.Other processing steps can be as discussed in connection with FIGS. 10and 11. The result is that envelope packets are formed with arecesscontaining layer extending between end seals (e.g., 17 and 18 asillustrated in FIG, 1), and united with those end seals, but not unitedcontinuously over the inner surfaces of either base polymeric filmstructure forming the walls of the packets. Upon inversion, asillustrated in FIGS. 2-4 inclusive, the band or width ofrecess-containing sheet material in such packets is exposed upon one orthe other side of the inverted envelope pocket, ready for use inapplying the packaged messy composition. In this type of structure,there need be no recess-containing material in the portion of theenvelope package where the temporary seal 19 is formed. Also, theearflaps 20 and.2l may conveniently be free of a recess-containingcoating. But if a recess-containing layer free of messy ingredients isdesired for finish shining or the like after application of messyingredients, it is conveniently made available by employing a band orwidth of separate recess-containing sheet material so wide as to extendthrough the temporary seal 19 and outwardly as an extra flapintermediate earflaps 20 and 21.

Illustrative messy spreadable compositions desirably packaged as taughtherein are metal polishes (e.g., polishes containing, for example,finely divided pigment size abrasivelike particles of precipitatedchalk, plus a film-forming organic compound such as an alkyl thiol, anda volatile solvent, suitably organic in nature, for the film-formingorganic compound). An illustrative shoe polish may comprise a waxemulsion (e.g., camauba wax in water), a binder or strength-impartingtack-free film-forming organic material (e.g., a polymeric acrylic resinemulsion), leveler-type ingredients which reduce surface tension of anapplied film (e.g., butoxyethyl phosphate, alcohols, etc.), pigmentsized particles such as carbon black, and a diluent such as water.Cleansing compositions of spreadable character may include suchingredients as a detergent, a humectant, an astringent (e.g., particlesof aluminum sulfate), and drying agent such as alcohol. Sterile ornonsterile composition may be packaged according to this teaching.Insect repellants, soaps, abrasive materials,

even powdery compounds are but further illustrations of the almostlimitless variety of compositions which may be packaged in therelatively flat-type envelopes using the principles hereof.

Generally, the quantity of composition in each envelope will not exceedabout 2 or possibly 3 cubic centimeters in volume; although a volume shigh as 5 (or even possibly cubic centimeters may be so packaged.Sometimes a volume as low as 0.001 cubic centimeter is all that may beneeded (as, for example, in packaging a sample for a potential user totest to determine suitability in a particular application beforepurchasing bulk quantities).

As an alternate to printing identifying indicia or instructions uponsheet material of an envelope of the invention, or in addition to sodoing, a label flap or sheet carrying such data may be attached to anenvelope, preferably to a sealed area of the sheet material or to anearflap. Where the package is to be hung on a hook for display purposes,a small hole may be punched through a relatively wide seal area orthrough an earflap.

That which is claimed is:

I. As a new package article: a disposable flexible envelopelikecontainer convertible to a pocket applicator, said container havingopposing walls formed of flexible sheet material, a spreadablecomposition within the envelope cavity between said opposing walls ofsaid container, said flexible sheet material comprising a flexibleorganic polymeric film substantially impervious to said composition,recess-contain ing layer means fixed within said envelope cavity andcarrying at least a portion of said spreadable composition withinrecesses thereof, the sheet material forming said opposing walls beingunited along all portions thereof immediately adjacent the peripherallimits of said envelope cavity, with all portions in face-to-facerelationship adjacent said peripheral limits being united by sealstructures, the expanse of said sheet material forming each saidopposing wall being sufficient in size to extend beyond a seal structurealong one edge of said envelope cavity to form a pair of outwardlyprojecting earflaps for finger gripping, said seal structure along saidone edge being temporary and rupturable and all other seal structuresadjacent the peripheral limits of said envelope cavity being permanent,and said earflaps being each adapted to be gripped between a thumb andforefinger and drawn apart to rupture the temporary seal of said oneedge and simultaneously form said container into a pocket capable ofbeing turned inside out to place said recess-containing layer meanscarrying said spreadable composition exterior to said inverted pocket,whereby fingers inserted into said inverted pocket are protected againstcontamination during hand application of said composition.

2. The article of claim 1 herein said temporary seal structure of saidone edge is at least 5 centimeters and no greater than centimeters intotal length, with the maximum depth dimension of said envelope cavitydownwardly from said one edge being no greater than l0 centimeters andbeing less than the length of said one edge.

3. The article of claim 1 wherein said temporary seal structure of saidone edge is no longer than l0 centimeters and the depth dimension ofsaid cavity downwardly from said one edge is no greater than 6centimeters.

4. The article of claim 1 wherein said outwardly projecting earflaps areof substantially equal size.

5. The article of claim 1 wherein the seal structures compriseheat-unified thermoplastic material.

6. The article of claim 1 wherein the polymeric film of the sheetmaterial comprises thermoplastic polymeric resin.

7. The article of claim 1 wherein the polymeric film comprises alaminate having a substantially nonthermoplastic polymeric resin filmand a thermoplastic readily heatsealable polymeric coating permanentlyadhered thereto.

8. The article of claim 1 wherein said recess-containing layer meansconsists essentially of an exposed recess-containing)la1yer united toone surface of said polymeric film.

. he article of claim 8 wherein said exposed recess-containing layercomprises fibrous elements.

10. The article of claim 8 wherein said exposed recess-containing layerconsists essentially of thermoplastic fibrous elements.

U. The article of claim 8 wherein the temporary seal structure of saidone edge is a heat seal structure and comprises an interposed layer oforganic resin material within the temporarily heat-sealed portion of thefibrous layer surfaces of the sheet material, said interposed resinlayer being characterized by having at least one surface of acomposition not activated to adhesiveness at the temperature at whichthe fibrous layers of said sheet material are activated during heatsealing, the temperature of formation of said temporary seal beinginsufficient to activate said composition of said one surface of saidlayer, whereby said fibrous layer of said sheet material temporarilyunited to said one surface of said layer is separable therefrom by ahand pulling force without forming strings of torn material at saidtemporary heat seal structure.

12. The article of claim 1 wherein said recess-containing layer means isaffixed within the cavity of said envelopelike container by a permanentheat seal.

13. The article of claim 1 wherein said outwardly projecting earflapsare sealed together at the outer peripheral limits thereof and a tearstrip extends along said seal at said outer peripheral limits for rapidseparation of said peripherally sealed earflaps.

14. The method of preparing a pocket applicator for applying a limitedquantity of spreadable composition to a surface, comprising grippingeach earflap of the article of claim 1 between a thumb and forefinger,pulling said earflaps apart by hand a distancejust sufficient to causerupture and opening of said temporary seal of said one edge of saidarticle, to thereby convert said article into an open pocket, invertingsaid pocket to place the recess-containing layer means thereof carryingsaid spreadable composition exterior to said inverted pocket, andinserting fingers of one hand into said inverted pocket.

15. The article of claim 1 wherein the maximum depth dimension of saidenvelope cavity downwardly from said temporary seal structure along saidone edge is less than the length of said temporary seal structure.

16. The article of claim 15 wherein said maximum depth dimension is nogreater than one-half the length of said temporary seal.

17. The article of claim 15 wherein the configuration of said temporaryseal structure along said one edge presents a peak portion whichprovides a starting point for said rupture of said temporary seal.

18. The article of claim 1 wherein said flexible organic polymeric filmcomprises a polymer of polyethylene terephthalate.

19. The article of claim 1 wherein the temporary seal structure of saidone edge comprises an interposed layer structure between the opposingwalls of sheet material in said temporary seal structure, one surface ofsaid interposed layer structure being permanently united to one of saidopposing walls in said temporary seal structure, and the other surfaceof said interposed layer structure being rupturally united to the otherof said opposing walls in said temporary seal structure.

1. As a new package article: a disposable flexible envelopelikecontainer convertible to a pocket applicator, said container havingopposing walls formed of flexible sheet material, a spreadablecomposition within the envelope cavity between said opposing walls ofsaid container, said flexible sheet material comprising a flexibleorganic polymeric film substantially impervious to said composition,recess-containing layer means fixed within said envelope cavity andcarrying at least a portion of said spreadable composition withinrecesses thereof, the sheet material forming said opposing walls beingunited along all portions thereof immediately adjacent the peripherallimits of said envelope cavity, with all portions in face-to-facerelationship adjacent said peripheral limits being uniteD by sealstructures, the expanse of said sheet material forming each saidopposing wall being sufficient in size to extend beyond a seal structurealong one edge of said envelope cavity to form a pair of outwardlyprojecting earflaps for finger gripping, said seal structure along saidone edge being temporary and rupturable and all other seal structuresadjacent the peripheral limits of said envelope cavity being permanent,and said earflaps being each adapted to be gripped between a thumb andforefinger and drawn apart to rupture the temporary seal of said oneedge and simultaneously form said container into a pocket capable ofbeing turned inside out to place said recess-containing layer meanscarrying said spreadable composition exterior to said inverted pocket,whereby fingers inserted into said inverted pocket are protected againstcontamination during hand application of said composition.
 2. Thearticle of claim 1 herein said temporary seal structure of said one edgeis at least 5 centimeters and no greater than 15 centimeters in totallength, with the maximum depth dimension of said envelope cavitydownwardly from said one edge being no greater than 10 centimeters andbeing less than the length of said one edge.
 3. The article of claim 1wherein said temporary seal structure of said one edge is no longer than10 centimeters and the depth dimension of said cavity downwardly fromsaid one edge is no greater than 6 centimeters.
 4. The article of claim1 wherein said outwardly projecting earflaps are of substantially equalsize.
 5. The article of claim 1 wherein the seal structures compriseheat-unified thermoplastic material.
 6. The article of claim 1 whereinthe polymeric film of the sheet material comprises thermoplasticpolymeric resin.
 7. The article of claim 1 wherein the polymeric filmcomprises a laminate having a substantially nonthermoplastic polymericresin film and a thermoplastic readily heat-sealable polymeric coatingpermanently adhered thereto.
 8. The article of claim 1 wherein saidrecess-containing layer means consists essentially of an exposedrecess-containing layer united to one surface of said polymeric film. 9.The article of claim 8 wherein said exposed recess-containing layercomprises fibrous elements.
 10. The article of claim 8 wherein saidexposed recess-containing layer consists essentially of thermoplasticfibrous elements.
 11. The article of claim 8 wherein the temporary sealstructure of said one edge is a heat seal structure and comprises aninterposed layer of organic resin material within the temporarilyheat-sealed portion of the fibrous layer surfaces of the sheet material,said interposed resin layer being characterized by having at least onesurface of a composition not activated to adhesiveness at thetemperature at which the fibrous layers of said sheet material areactivated during heat sealing, the temperature of formation of saidtemporary seal being insufficient to activate said composition of saidone surface of said layer, whereby said fibrous layer of said sheetmaterial temporarily united to said one surface of said layer isseparable therefrom by a hand pulling force without forming strings oftorn material at said temporary heat seal structure.
 12. The article ofclaim 1 wherein said recess-containing layer means is affixed within thecavity of said envelopelike container by a permanent heat seal.
 13. Thearticle of claim 1 wherein said outwardly projecting earflaps are sealedtogether at the outer peripheral limits thereof and a tear strip extendsalong said seal at said outer peripheral limits for rapid separation ofsaid peripherally sealed earflaps.
 14. The method of preparing a pocketapplicator for applying a limited quantity of spreadable composition toa surface, comprising gripping each earflap of the article of claim 1between a thumb and forefinger, pulling said earflaps apart by hand adistance just sufficient to cause rupture and opeNing of said temporaryseal of said one edge of said article, to thereby convert said articleinto an open pocket, inverting said pocket to place therecess-containing layer means thereof carrying said spreadablecomposition exterior to said inverted pocket, and inserting fingers ofone hand into said inverted pocket.
 15. The article of claim 1 whereinthe maximum depth dimension of said envelope cavity downwardly from saidtemporary seal structure along said one edge is less than the length ofsaid temporary seal structure.
 16. The article of claim 15 wherein saidmaximum depth dimension is no greater than one-half the length of saidtemporary seal.
 17. The article of claim 15 wherein the configuration ofsaid temporary seal structure along said one edge presents a peakportion which provides a starting point for said rupture of saidtemporary seal.
 18. The article of claim 1 wherein said flexible organicpolymeric film comprises a polymer of polyethylene terephthalate. 19.The article of claim 1 wherein the temporary seal structure of said oneedge comprises an interposed layer structure between the opposing wallsof sheet material in said temporary seal structure, one surface of saidinterposed layer structure being permanently united to one of saidopposing walls in said temporary seal structure, and the other surfaceof said interposed layer structure being rupturally united to the otherof said opposing walls in said temporary seal structure.